SECTION 12 – HELICAL GEARS

DESIGN PROBLEMS

701. For continuous duty in a speed reducer, two helical gears are to be rated at 7.4 hp
at a pinion speed of 1750 rpm; m w ≈ 2.75 ; the helix angle 15o ; 20o F.D. teeth in
the normal plane; let N p = 21 teeth, and keep b < 2 D p . Determine the pitch, face,
N g , and the material and heat treatment. Use through-hardened teeth with a
maximum of 250 BHM (teeth may be cut after heat treatment).

Solution:
ψ = 15o
φn = 20o
πD p n p
vm =
12
N p 21
Dp = =
Pd Pd
n p = 1750 rpm
 21 
π  (1750)
 Pd  9621
vm = =
12 Pd
33,000hp (33,000 )(7.4 )
Ft = = = 25.38 Pd
vm  9621 
 
P
 d 
b ≤ 2 Dp
 21  42
b = 2  =
 Pd  Pd
0.05vm (Ft + Cb cos 2 ψ )cosψ
Fd = Ft + 1
lb
0.05vm + (Ft + Cb cos ψ )
2 2

Table AT 25
Assume C = 1660
ψ = 15o
 9621    42  
0.05  25.38Pd + 1660  cos 2 15 cos15
 Pd    Pd  
Fd = 25.38Pd + 1
lb
 9621    42   2
0.05  + 25.38Pd + 1660  cos 2 15
 Pd    Pd  

Page 1 of 14
 SECTION 12 – HELICAL GEARS

465  65050 
 25.38 Pd + 
Pd  Pd 
Fd = 25.38 Pd + 1
lb
481  65050  2
+  25.38 Pd + 
Pd  Pd 
For continuous service: Fw ≥ Fd
bD pQK g
Fw =
cos 2 ψ
2mg 2(2.75)
Q= = = 1.467
mg + 1 2.75 + 1
Table At 26, Bhn = 250
Sum of BHN = 500, φn = 20o
K g = 131
 42  21  (1.467 )(131) 181,670
Fw =    2
=
 Pd  Pd  cos 15 Pd2
Fw ≥ Fd
By trial and error method

Pd Fd Fw
7 3967 3708
6 4758 5046

use Pd = 6
21 21
Dp = = = 3.5 in
Pd 6
42 42
b= = = 7 in
Pd 6
9621 9621
vm = = = 1604 fpm
Pd 6
Fig. AF 19, permissible error = 0.0018 in
Fig. AF 20
Use carefully cut gears, Pd = 6
Error = 0.001 in is o.k.

For material
Strength
sbY cosψ
Fs =
K f Pd

Page 2 of 14
 SECTION 12 – HELICAL GEARS

Np 21
N ep = = = 23
cos ψ cos3 15
3

Table AT 24, Load near middle

N ep = 23 , φn = 20o FD
Y = 0.565
assume K f = 2.0
Fs = N sf Fd
assume N sf = 2.0
s (7 )(0.565) cos15
= (4758)(2)
(2 )(6)
s = 29,892 psi
s
use sn = u
3
su = 3(29,892) = 89,676 psi
Use C1050, OQT 1100 F,
su = 122 ksi , BHN = 248 < 250

Ans.
Pd = 6
b = 7 in
N g = mw N p = (2.75)(21) = 58
Material. C1050, OQT 1100 F

703. A pair of helical gears, subjected to heavy shock loading, is to transmit 50 hp at

3
1750 rpm of the pinion.; mg = 4.25 ; ψ = 15o ; minimum D p = 4 in. ; continuous
4
o
service, 24 hr/day; 20 F.D. teeth in the normal plane, carefully cut; through-
hardened to a maximum BHN = 350. Decide upon the pitch, face width, material
and its treatment.

Solution:
π (4.75)(1750)
vm = = 2176 fpm
12
33,000hp (33,000 )(50 )
Ft = = = 758 lb
vm (2176)
Dynamic load:
Fd = Ft +
( )
0.05vm Ft + Cb cos 2 ψ cosψ
lb
1
( 2
0.05vm + Ft + Cb cos ψ 2 )
Fig. AF 19, vm = 2176 fpm
Permissible error = 0.0014 in

Page 3 of 14
 SECTION 12 – HELICAL GEARS

Use carefully cut gears, e = 0.001 in , Pd = 5 as standard

Table AT 25,
Steel and steel, 20o FD
C = 1660

Fd = 758 +
( )
0.05(2176) 758 + 1660b cos 2 15 cos15
lb
1
(
0.05(2176) + 758 + 1660b cos 152
)
2

105.1(758 + 1548.8b )
Fd = 758 + 1 lb
108.8 + (758 + 1548.8b )2
Wear load:
bD pQK g
Fw =
cos 2 ψ
2mg 2(4.25)
Q= = = 1.619
mg + 1 4.25 + 1
Table At 26, 20o FD,
Sum of BHN =2(350)=700
K g = 270
b(4.75)(1.619 )(270 )
Fw = = 2225b
cos 2 15
2π
Fw ≥ Fd , bmin = 2 Pa = = 4.69 in.
Pd tanψ
By trial and error method

b Fd Fw
5 5203 11125
6 5811 13350

use b = 5 in

Material:
Strength:
sbY sbY cosψ
Fs = =
K f Pdn K f Pd
Np
N ep =
cos3ψ
N p = Pd D p = (5)(4.375) = 22
22
N ep = = 25
cos3 15
Table AT 24, Load near middle

Page 4 of 14
 SECTION 12 – HELICAL GEARS

N ep = 25 , φn = 20o FD
Y = 0.580
assume K f = 1.7
s (5)(0.580) cos15
Fs = = 0.32955s
(1.7 )(5)
Fs = N sf Fd
for 24 hr/day service, heavy shock loading
N sf = 1.75
0.32955s = (1.75)(5203)
s = 27,629 psi
s
use sn = u
3
su = 3(27,629) = 82,887 psi
Table AT 9
Use 4150, OQT 1200 F,
su = 159ksi , BHN = 331 < 350
Ans.
Pd = 5
b = 5 in
Material. 4150, OQT 1200 F

705. Design the teeth for two herringbone gears for a single-reduction speed reducer
with mw = 3.80 . The capacity is 36 hp at 3000 rpm of the pinion; ψ = 30o ; F.D.
teeth with φn = 20o . Since space is at a premium, the initial design is for N p = 15
teeth and carburized teeth of AISI 8620; preferably b < 2 D p .

Solution:
N 15
Dp = p =
Pd Pd
b ≈ 2Dp
30
b = 2 Dp =
Pd
πD p n p
vm =
12
 15 
π  (3000)
P
vm =  d 
11,781
=
12 Pd

Page 5 of 14
 SECTION 12 – HELICAL GEARS

33,000hp (33,000 )(36 )

Ft = = = 101Pd
vm  11,781 
 
 Pd 
Dynamic load
Fd = Ft +
( )
0.05vm Ft + Cb cos 2 ψ cosψ
lb
1
( 2
0.05vm + Ft + Cb cos ψ 2 )
o
φn = 20
ψ = 30 o
Assume C = 1660 , Table AT 25, 20o FD
 11,781    30  
0.05  101Pd + 1660  cos 2 30 cos 30
 Pd    Pd  
Fd = 101Pd + 1
lb
 11,781    30   2
0.05  + 101Pd + 1660  cos 2 30
 Pd    Pd  
510  37,350 
101Pd + 
Pd  Pd 
Fd = 101Pd + 1
lb
589  37,350  2
+ 101Pd + 
Pd  Pd 
Wear load
bD pQK g
Fw =
cos 2 ψ
2 mg 2(3.80)
Q= = = 1.583
mg + 1 3.80 + 1
For AISI 8620, carburized, 20o FD
K g = 750 for 1010 cycles
 30  15  (1.583)(750) 712,350
Fw =    2
=
 Pd  Pd  cos 30 Pd2
By trial and error, Fw ≥ Fd
Pd Fd Fw
5 4433 28,494
4 5454 44,522
6 3817 19,788
8 3173 11,130
9 3008 8794

For carefully cut gears, e = 0.001

vmax = 1400 fpm (Fig. AF 9)

Page 6 of 14
 SECTION 12 – HELICAL GEARS

11,781
Pd vm =
Pd
5 2356.2
4 1963.5
6 1683
8 1473
9 1309 fpm

use Pd = 9
Fd = 3008 lb
Fw = 5794 lb > Fd
30 30
b= = = 3.3 in
Pd 9
use b = 3.0 in

To check for strength

sbY sbY cosψ
Fs = =
K f Pdn K f Pd
Np
N ep =
cos3ψ
N p = 15
15
N ep = = 23
cos3 30
Table AT 24, Load near middle
N ep = 23 , φn = 20o FD
Y = 0.565
assume K f = 1.7
8620, SOQT 450, su = 167 ksi
s
sn = u
3
su 167
sn = = = 83.5
2 2
Fs =
(83,500)(3.0)(0.565)cos 30 = 8011 lb > F (= 3008 lb )
d
(1.7)(9)
Designed Data:
Pd = 9
b = 3.0 in
N p = 15
N g = mw N p = (3.8)(15) = 57

Page 7 of 14
 SECTION 12 – HELICAL GEARS

N p 15
Dp = = = 1.67 in
Pd 9
N 57
Dg = g = = 6.33 in
Pd 9

CHECK PROBLEMS

707. The data for a pair of carefully cut gears are: Pdn = 5 , φn = 20o ,ψ = 12o ,
b = 3.5 in. , N p = 18 , N g = 108 teeth; pinion turns 1750 rpm. Materials: pinion,
SAE 4150, OQT to BHN = 350; gear, SAE 3150, OQT to BHN = 300. Operation
is with moderate shock for 8 to 10 hr./day. What horsepower may be transmitted
continuously?

Solution:
N
Dp = p
Pd
Pd = Pdn cosψ = (5)cos15 = 4.89
18
Dp = = 3.681 in
4.89

Wear load
bD pQK g
Fw =
cos 2 ψ
b = 3.5 in.
2Ng 2(108)
Q= = = 1.7143
N p + N g 18 + 108
Table AT 26, φn = 20o
Sum of BHN = 350 + 300 = 650
K g = 233

Fw =
(3.5)(3.681)(1.7143)(233) = 5379 lb
cos 2 12
Strength of gear
sbY
Fs = lb
K f Pdn
For gear: SAE 3150, OQT to BHN = 300
su = 151 ksi
sn = 0.5su = 0.5(151) = 75.5 ksi
Ng 108
N eg = = = 116
cos ψ cos3 12
3

Page 8 of 14
 SECTION 12 – HELICAL GEARS

Table AT 24, Load near middle, φn = 20o

Y = 0.763
snY = (75.5)(0.763) = 57.6
For pinion: SAE 4150, OQT to BHN = 350
su = 0.5BHN = 0.5(350) = 175 ksi
sn = 0.5su = 0.5(175) = 87.5 ksi
Np 18
N ep = = = 19
cos ψ cos3 12
3

Table AT 24, Load near middle, φn = 20o

Y = 0.534
snY = (87.5)(0.534) = 46.7

Therefore use pinion as weak

Assume K f = 1.7

Fs =
(87,500)(3.5)(0.534) = 19,240 lb
(1.7 )(5)
For moderate shock, 8 to 10 hr./day
Use N sf = 1.5
Fs ≥ N sf Fd
19,240 = 1.5Fd
Fd ≤ 12,827 lb
Therefore use Fd = Fw = 5379 lb
0.05vm (Ft + Cb cos 2 ψ )cosψ
Fd = Ft + 1
lb
0.05vm + (Ft + Cb cos 2 ψ )2
Fig. AF 20, carefully cut gears, Pdn = 5 , e = 0.001 in
Table AT 25, steel and steel, 20o FD
C = 1660
πD p n p π (3.681)(1750)
vm = = = 1686 fpm
12 12
Fd = Ft +
[ ]
0.05(1686) Ft + 1660(3.5) cos 2 12 cos12
lb
1
[ ]
0.05(1686) + Ft + 1660(3.5) cos 12 2
2

82.46[Ft + 5559]
Fd = Ft + 1
= 5379 lb
84.3 + [Ft + 5559]2
Trial and error
Ft = 1800 lb
Fv
hp = t m =
(1800)(1686) = 92 hp
33,000 33,000

Page 9 of 14
 SECTION 12 – HELICAL GEARS

708. Two helical gears are used in a single reduction speed reducer rated at 27.4 hp at
a motor speed of 1750 rpm; continuous duty. The rating allows an occasional 100
% momentary overload. The pinion has 33 teeth. Pdn = 10 , b = 2 in. , φn = 20o ,
ψ = 20o , mw = 2.82 . For both gears, the teeth are carefully cut from SAE 1045
with BHN = 180. Compute (a) the dynamic load, (b) the endurance strength;
estimate K f = 1.7 . Also decide whether or not the 100 % overload is damaging.
(c) Are these teeth suitable for continuous service? If they are not suitable
suggest a cure. (The gears are already cut.)

Solution:
N
Dp = p
Pd
Pd = Pdn cosψ = (10) cos15 = 9.66
33
Dp = = 3.42 in
9.66
πD p n p π (3.42)(1750)
vm = = = 1567 fpm
12 12
33,000hp 33,000(27.4 )
Ft = = = 577 lb
vm 1567
(a) Dynamic load
0.05vm (Ft + Cb cos 2 ψ )cosψ
Fd = Ft + 1
lb
0.05vm + (Ft + Cb cos 2 ψ )2
Fig. AF 20, carefully cut gears, Pdn = 10 , e = 0.001 in
Table AT 25, steel and steel, 20o FD
C = 1660
b = 2 in

Fd = 577 +
[ ]
0.05(1567 ) 577 + 1660(2)cos 2 15 cos15
= 2578 lb
1
[
0.05(1567 ) + 577 + 1660(2)cos 15
2
]2

(b) Endurance strength

sbY
Fs = lb
K f Pdn
For SAE 1045, BHN = 180
su = 0.5BHN = 0.5(180) = 90 ksi
sn = 0.5su = 0.5(90) = 45 ksi
Np 33
N ep = = = 37
cos ψ cos3 15
3

Table AT 24, Load near middle, φn = 20o

Page 10 of 14
 SECTION 12 – HELICAL GEARS

Y = 0.645

K f = 1 .7

Fs =
sbY
=
(45,000)(2)(0.645) = 3415 lb
K f Pdn (1.7 )(10)
For 100 % overload
Ft = 2(577 ) = 1154 lb
0.05vm (Ft + Cb cos 2 ψ )cosψ
Fd = Ft + 1
lb
0.05vm + (Ft + Cb cos ψ )
2 2

Fd = 1154 +
[ ]
0.05(1567 ) 1154 + 1660(2)cos 2 15 cos15
= 3475 lb
1
[
0.05(1567 ) + 1154 + 1660(2) cos 15 2
]
2

Since Fs ≈ Fd , 100 % overload is not damaging

bD pQK g
(c) Fw =
cos 2 ψ
b = 2 in.
2mw 2(2.82 )
Q= = = 1.476
mw + 1 2.82 + 1
Table AT 26, φn = 20o
Sum of BHN = 2(180) = 360
K g = 62.5

Fw =
(2)(3.42)(1.476)(62.5) = 676 lb < F (= 2578 lb )
d
cos 2 15
Therefore not suitable for continuous service.
Cure: Through hardened teeth
For Bhn
2578
Kg = (62.5) = 238
676
min Bhn = 0.5(650) = 325

709. Two helical gears are used in a speed reducer whose input is 100 hp at 1200 rpm,
from an internal combustion engine. Both gears are made of SAE 4140, with the
pinion heat treated to a BHN 363 – 415, and the gear to 321 – 363; let the teeth
be F.D.; 20o pressure angle in the normal plane; carefully cut; helix angle
ψ = 15o ; N p = 22 , N g = 68 teeth; Pd = 5 , b = 4 in . Calculate the dynamic load,
the endurance strength load, and the limiting wear load for the teeth. Should these
gears have long life if they operate continuously? (Data courtesy of the Twin
Disc Clutch Co.)

Solution:

Page 11 of 14
 SECTION 12 – HELICAL GEARS

N p 22
Dp = = = 4.4 in
Pd 5
πD p n p π (4.4)(1200)
vm = = = 1382 fpm
12 12
33,000hp 33,000(100 )
Ft = = = 2388 lb
vm 1382
Dynamic load
0.05vm (Ft + Cb cos 2 ψ )cosψ
Fd = Ft + 1
lb
0.05vm + (Ft + Cb cos ψ )2
2

Fig. AF 20, carefully cut gears, Pdn = 5 , e = 0.001 in

Table AT 25, steel and steel, 20o FD
C = 1660
b = 4 in

Fd = 2388 +
[ ]
0.05(1382) 2388 + 1660(4) cos 2 15 cos15
= 5930 lb
1
[
0.05(1382 ) + 2388 + 1660(4)cos 152
]
2

Endurance strength load

sbY cosψ
Fs = lb
K f Pd
Assume K f = 1.7
Pinion
sn = 0.25BHN = 0.25(363) = 90.75 ksi
Np 22
N ep = = = 25
cos ψ cos3 15
3

Table AT 24, Load near middle, φn = 20o

Y = 0.580
sbY cosψ (90,750)(4 )(0.580) cos15
Fs = = = 23,925 lb
K f Pd (1.7 )(5)
Gear
sn = 0.25BHN = 0.25(321) = 80.25 ksi
Np 68
N ep = = = 75
cos ψ cos3 15
3

Table AT 24, Load near middle, φn = 20o

Y = 0.735
sbY cosψ (80,250 )(4)(0.735)cos15
Fs = = = 26,811 lb
K f Pd (1.7 )(5)
use Fs = 23,925 lb

Page 12 of 14
 SECTION 12 – HELICAL GEARS

Limiting Wear Load

bD pQK g
Fw =
cos 2 ψ
Table AT 26, φn = 20o
Sum of BHN = 684 to 778 use 700
K g = 270
2Ng 2(68)
Q= = = 1.511
N p + N g 22 + 68

Fw =
(4)(4.4)(1.511)(270) = 7696 lb
cos 2 15
Since Fw (= 7696 lb ) > Fd (= 5930 lb ) these gears have long life if they operate
continuously.

CROSSED HELICAL

710. Helical gears are to connect two shafts that are at right angles
( N1 = 20 , N 2 = 40 , Pdn = 10 ,ψ 1 = ψ 2 = 45o ). Determine the center distance.

Solution:
πD cosψ 1
N1 = 1 = Pdn D1 cosψ 1
Pcn
20 = (10)(D1 )cos 45
D1 = 2.83 in
N 2 = Pdn D2 cosψ 2
40 = (10)(D2 )cos 45
D2 = 5.66 in
C = 12 (D1 + D2 ) = 12 (2.83 + 5.66) = 4.25 in

712. Two shafts that are at right angles are to be connected by helical gears. A
tentative design is to use N1 = 20 , N 2 = 60 , Pdn = 10 , and a center distance of 6
in. What must be the helix angles?

Solution:
Σ = ψ 1 +ψ 2 = 90o
N1
D1 =
Pdn cosψ 1
N2
D2 =
Pdn cosψ 2
C = 2 (D1 + D2 )
1

Page 13 of 14
 SECTION 12 – HELICAL GEARS

N1 N2
2C = +
Pdn cosψ 1 Pdn cosψ 2
20 60
2(6 ) = +
10 cosψ 1 10 cosψ 2
2 6
12 = +
cosψ 1 cosψ 2
1 3
6= +
cosψ 1 cosψ 2
By trial and error method
1 3
6= +
cosψ 1 sinψ 1
ψ 1 = 39.5o
ψ 2 = 50.5o

- end -

Page 14 of 14